Collapsible box

ABSTRACT

A collapsible box with a plurality of sides connected at folding corners includes notches in the sides for accommodating hinge connectors which couple the sides together and allow the sides to be folded through a range of motion with respect to each other.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Patent Application No. 61/939,414, filed Feb. 13, 2014, which is incorporated herein by reference in its entirety.

BACKGROUND

Various different styles of wooden crates/boxes are available on the market today. One common type of wooden box is the plywood panel box 10, shown in FIG. 1, which includes a base 12 and a top 14 connected by four sides 16, only two of which are visible in FIG. 1. The top 14 can form an openable lid for the box 10. The base 12 may rest on a pallet 18, or may be integrally provided with the pallet 18. Reinforcement members can be attached to the box 10; as shown herein, the vertical and horizontal corners of the box 10 can be reinforced with corner members 20 and the top 14 and at least some of the sides 16 of the box 10 can be reinforced with mid-panel members 22. The reinforcement members 20, 22 typically comprise sawn lumber. The box 10 is assembled by connecting the various components together with mechanical fasteners 24, such as staples or nails.

FIGS. 2A-2C schematically illustrate some typical styles of a related product, the collapsible and reusable wooden box 26, which is available in a variety of configurations. The box 26 includes four sides 28 which are joined at vertical corners 30; for purposes of simplification, bases and tops are not shown on the boxes 26 of FIGS. 2A-2C. The main variable between styles of the collapsible and reusable wooden box 26 is the number of folding vertical corners 30. FIG. 2A shows one typical rectilinear box 26 in which two of the opposing vertical corners 30 fold and the other two opposing vertical corners 30 are attached by the end user. The folding corners 30 include hinge connectors 32 which permit the sides 28 of the box 26 to be folded at the corners 30. FIG. 2B shows another typical rectilinear box 26 in which all four vertical corners 30 fold and include hinge connectors 32. FIG. 2C shows yet another common rectilinear box 26 in which an additional vertical fold 34 is placed at the mid-point of one of the sides 28. Another style of collapsible and reusable wooden box requires all four corners to be attached by the end user via a supplied connection (not shown).

BRIEF SUMMARY

According to one embodiment of the invention, a collapsible box includes a plurality of sides, each side having at least one notched edge, with at least one notch therein, the at least one notch in register with a notch on an adjacent one of the sides, at least one hinge connector connecting two of the sides and having first and second fasteners mounted to a respective one of the two sides, and a flexible strap between the first and second fasteners and aligned with the notches in register, whereby, due to the aligned strap and notches, the two sides can be folded through a range of motion with respect to each other.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a prior art plywood panel box;

FIG. 2A is a schematic view of a first style of collapsible and reusable wooden box of the prior art;

FIG. 2B is a schematic view of a second style of collapsible and reusable wooden box of the prior art;

FIG. 2C is a schematic view of a third style of collapsible and reusable wooden box of the prior art;

FIG. 3 is a perspective view of a collapsible box according to one embodiment of the invention;

FIG. 4 is an elevation view of one side of the box of FIG. 3;

FIG. 5 is an exploded view of a hinge connector for the box of FIG. 3;

FIGS. 6-8 illustrate the steps of a method for attaching two sides of the box of FIG. 3;

FIG. 9 is a perspective view of the attached sides of the box of FIG. 3 in an upright and approximately 45° folded position;

FIGS. 10-15 illustrate the steps of a method for assembling the box of FIG. 3;

FIG. 16 illustrates the box of FIG. 3 partially disassembled in a collapsed configuration;

FIG. 17 is a perspective view of a hinge connector according to a second embodiment of the invention;

FIG. 18 is an exploded view of the box with the hinge connector of FIG. 17;

FIG. 19 is an assembled view of the box with the hinge connector of FIG. 17; and

FIGS. 20-22 are side views showing two sides for a box according to a third embodiment of the invention.

DETAILED DESCRIPTION

The invention relates to a collapsible box or crate. In one of its aspects, the invention relates to an improved collapsible and/or reusable wooden box which can be easily and conveniently assembled or disassembled as needed. Fields in which the invention has potential application include the protection, shipment and/or storage of goods, including a wide variety of products. As used herein, the terms “crate” and “box” are interchangeable.

FIG. 3 is a perspective view of a collapsible box 40 according to one embodiment of the invention. The box includes a base 42 and a top 44 connected by four sides 46, only two of which are visible in FIG. 1. The top 44 can form an openable lid for the box 40. The four sides 46 which are joined at vertical corners 48. At least one hinge connector 50 is provided at each vertical corner 48 to permit folding. The number of hinge connectors 50 can vary, as explained in more detail below.

The collapsible box 40 shown herein is similar in style to the prior art collapsible box shown in FIG. 2B, in that all four vertical corners 48 fold. However, it is also contemplated that the collapsible box 40 can be configured in a style similar to the prior art collapsible box shown in FIG. 2A in which two of the opposing vertical corners 48 fold and are attached by at least one hinge connector 50, and the other two opposing vertical corners 48 are attached by the end user and are not provided with at least one hinge connector 50. In yet another contemplated configuration, the collapsible box 40 can have a style similar to the prior art collapsible box shown in FIG. 2C in which all four vertical corners 48 fold and further in which an additional vertical fold (not shown) is placed at the mid-point of at least one of the sides 46 and provided with at least one hinge connector 50.

FIG. 4 is an elevation view of one side 46 of the box 40 from FIG. 3. Each side 46 can be formed from a panel 52 which includes opposing horizontal edges 54 and opposing vertical edges 56, only one of which is visible in FIG. 4. The panel 52 can be cut from ¼″ or thicker plywood. For a side 46 having a thickness of ¼″, a 5-ply birch plywood panel can be used.

At least one notch 58 is formed in the vertical edges 56 of the panel 52. The at least one notch 58 can be formed by cutting on a CNC machine or other appropriate equipment. As shown, two spaced notches 58 are provided, although other numbers of notches are possible. The number of notches 58 can depend on the overall dimensions of the box 40 and/or the particular crating application. For a box having dimensions of 12″×12″×12″ or 24″×24″×24″, two notches can be provided for each folding corner. A 36″×36″×36″ box can have three or more notches provided for each folding corner.

Each notch 58 shown includes a rectilinear cut-out in the vertical edge 56, with two opposing horizontal notch edges 60 joined with a vertical notch edge 62 which is spaced inwardly from the vertical edge 56 of the panel 52. Other notch profiles are also possible.

The depth D of the notch 58 in the horizontal direction, which substantially corresponds to the length of the horizontal notch edges 60, will vary depending on the panel thickness, but for ¼″ panel material, the depth D will be approximately 3/16″ to ¼″. The width W of the notch 58 in the vertical direction, which substantially corresponds to the length of the vertical notch edge 62, will also vary. One suitable width W for ¼″ panel material is approximately 2¼″ to 2½″.

FIG. 5 is an exploded view of one suitable hinge connector 50 for the box 40 of FIG. 3. The hinge connector 50 includes a flexible and/or resilient strap 64 which extends over and is partially received within the aligned notches 58 of the sides 46 making up one of the vertical corners 48 of the box 40. The material for the strap 64 can vary, but is preferably adapted to bend through a range of motion from 0-180° as the sides 46 are folded. In one example, the strap 64 can be a thin hot dipped galvanized commercial steel strap. The thin steel strap allows the sides 46 to be folded and unfolded without metal fatigue.

The hinge connector 50 further includes a pair of mechanical fasteners which secure the strap 64 to the sides 46 making up one of the vertical corners 48 of the box 40. The mechanical fasteners shown are metal truss connector plates 66 having teeth or nails 67, which are placed over each end of the strap 64 and pressed into the sides 46. Using a strap 64 of suitable thinness in conjunction with the connector plates 66 is convenient, since connector plates 66 can penetrate the strap 64 and embed into the sides 46.

The size of the strap 64 and connector plates 66 can vary depending on the dimensions of the box 40 and number of notches 58. In one example, a 2″×3″ strap 64 can be used, with the 3″ length spanning across the vertical corner 48, in conjunction with a 1″×2″ metal connector plate 66 having slots running vertically.

The various specifications for the box 40 mentioned herein, including but not limited to materials and dimensions, are primarily for light duty applications. Heavy duty applications can be addressed by using thicker plywood and/or larger size straps 64 and connector plates 66. Also, the outside of the box 40 can optionally be reinforced, for example by adding sawn lumber reinforcement members similar to those shown in FIG. 1 to the outside of the box 40, without effecting its form and function. Also, while the materials for the box 40 described herein include plywood and sawn lumber, it is also within the scope of the invention to use other solid woods or other engineered woods, such as but not limited to laminated veneer lumber, laminated strand lumber, parallel strand lumber, and oriented strand board. In other embodiments of the invention, the sides 46 can be plastic, metal, or cardboard. In any of these embodiments, the sides 46 can be reinforced, laminated, or comprise a composite of materials.

A method for attaching two of the sides 46 together is illustrated in FIGS. 6-8. While shown with respect to sides 46 having two notches 58, it is understood that the method is applicable to sides 46 having any number of notches 58. As shown in FIG. 6, two panels 52 making up the sides 46 are placed side-by-side with their vertical edges 56 adjacent to each other and their respective notches 58 aligned. The vertical edges 56 are not butted against each other, but rather a small gap G is maintained between the panels 52. For ¼″ panels, the gap G may be approximately 0.125″. Next, as shown in FIG. 7, the hinge connector 50 is readied for attachment by positioning the strap 64 over the aligned notches 58 and by positioning the connector plates 66 over the ends of the strap 64. Finally, as shown in FIG. 8, the panels 52 are fastened together by pressing the connector plates 66 into the panels 52 through the strap 64.

FIG. 9 illustrates the final assembled panels 52 in an upright and approximately 45° folded position, though it is understood that the panels 52 may be pivoted through a range of motion from 0-180°. When folded, the strap 64 fits within the notches 58, between the horizontal notch edges 60.

A method of assembling the box 40 is illustrated in FIGS. 10-15. As shown in FIG. 10, the four panels 52 are placed in a row, with three sets of the vertical edges 56 adjacent to each other and gaps G therebetween. Next, the hinge connectors 50 can be attached to the panels 52 using the method generally outlined for FIGS. 6-8 to form three of the vertical corners 48, as shown in FIG. 11. A floor-type truss press (not shown) can optionally be used during this step, where the row of panels 52 are placed on the press and the connector places 66 are pressed into the panels 52 with the platens from the truss press. At this stage, the two outer vertical edges 56 on the end panels 52 remain unconnected.

Once the first three sets of vertical edges 56 are connected, the partially assembled panels 52 are then flipped over such that the hinge connectors 50 face down as shown in FIG. 12. The two end panels 52 are then folded over onto the two center panels 52 such that the end panels 52 meet at a mid-point to create a fourth set of adjacent vertical edges 56, as shown in FIG. 13. These vertical edges 56 are then connected in the same manner as the other three edge sets to form the fourth vertical corner 48, as shown in FIG. 14. Once completed, the assembled side panels 46 can be removed from the truss press fully intact.

Next, the assembled sides 46 can be set upright and unfolded to an orientation in which the vertical corners 48 are approximately 90°, as shown in FIG. 15. The base 42 and the top 44 can then be connected to the bottom and top of the sides 46, respectively. The top 44 can form an openable lid for the box 40.

The base 42 and top 44 can be secured to the sides 46 in a number of suitable ways. One option is using screws or staples. Another option for the top 44 is to use a metal connector plate and steel strap combination similar to those shown in FIG. 5 for the hinge connector 50, with the metal connector plate being attached to one side 46 only, such that the top 44 can pivot between open and closed positions. Other similar options for the top 44 might consist of nylon straps or hook-and-loop (Velcro®) straps.

One proposed base 42 and/or top 44 is shown in FIG. 15, and includes a panel 68 with trim 70 on the periphery of the inner surface of the panel 68. The trim 70 includes a 45° bevel cut 72 on the outside edge. By enlarging the rectangular shape of the trim 70, the bevel cut 72 will facilitate a close fit within the sides 46 of the box 40, while still allowing the top 44 to be attached to and removed from the box 40 as needed. The base 42 and/or top 44 can be combination of plywood and sawn lumber; in one example, the panel 68 is plywood and the trim 70 is sawn lumber. For a plywood panel 68 having a thickness of ¼, 1½″×1″ sawn lumber trim 70 can be used.

While shown as being identical in FIG. 15, the base 42 and top 44 can be dissimilar form each other. For example, as an alternative to the base 42 shown in FIG. 15, a pallet-style base 42 in which the base 42 comprises a pallet, with the side walls 46 secured to the pallet, similar to the base shown in FIG. 1.

FIG. 16 shows the box 40 partially disassembled in a collapsed configuration. In the collapsed configuration, the base 42 and top 44 of the box 40 are separated from the side walls 46 and rest on the still-assembled side walls 46, which have been folded flat. This collapsed configuration may be helpful when the box 40 is not in use or during shipping, as the box 40 can be conveniently stored or shipped in a flat pack configuration.

FIG. 17 is a perspective view of a hinge connector 74 according to a second embodiment of the invention. The hinge connector 74 can be used with the collapsible box 40 of FIGS. 3-16 in place of the hinge connector 50. The hinge connector 74 differs from the first embodiment hinge connector 50 in being a one-piece hinge rather than comprising multiple components. The hinge connector 74 includes a flexible and/or resilient strap 76 with mechanical fasteners for securing the strap 76 to the box 40 formed integrally with the strap 76. The mechanical fasteners shown include multiple teeth or nails 78 which are cut from the strap 76 itself. The formation of the nails 78 leaves corresponding slots 80 in the strap 76.

FIGS. 18 and 19 are an exploded view and an assembled view of the hinge connector 74 and the box 40. The strap 76 extends over and is partially received within the aligned notches 58 of the sides 46 making up one of the vertical corners 48 of the box 40. The hinge connector 74 can be attached to the panels 52 using the method generally outlined for FIGS. 6-8 to form the vertical corner 48, save for the nails 78 on the ends of the strap 76 being pressed directly into the panels 52 making up the vertical corner 48.

The material for the strap 76 can vary, but is preferably adapted to bend through a range of motion from 0-180° as the sides 46 are folded. In one example, the strap 76 can be a thin hot dipped galvanized commercial steel strap. The thin steel strap 76 allows the sides 46 to be folded and unfolded without metal fatigue of the hinge connector 74.

The nails 78 may be formed in different directions, such that the resulting slots 80 are arranged perpendicular to each other, i.e. parallel to either a short side 82 or a long side 84 of the rectangular strap 76. This permits a thin metal strap 76, one non-limiting example of which is 26 gauge steel having a thickness of 0.019″, to be used without the nails 78 folding over when pressed into the sides 46.

The size of the strap 76 can vary depending on the dimensions of the box 40 and number of notches 58. In one example, a 2″×4″ strap 76 can be used, with the 4″ length spanning across the vertical corner 48. In one example, a 3″×5″ strap 76 can be used, with the 5″ length spanning across the vertical corner 48.

FIGS. 20-22 are side views showing two sides 46 for a box 40 according to a third embodiment of the invention. The sides 46 can be used with the collapsible box 40 of any of the previous embodiments. The sides 46 are show as being connected by the hinged connector 74 of FIGS. 17-19, but it is understood that the sides 46 may also be connected by the hinge connector 50 of the first embodiment. Only two sides 46 are shown in FIGS. 20-22, but it is understood that all sides of the box 40 can be configured as shown.

The sides 46 differ from the previous embodiments in that the panels 52 are provided with a chamfer 86 on the vertical edge 56. The chamfers 86 may extend the entire length of the vertical edges 56. The chamfers 86 are provided on the opposite side of the panel 52 as the hinge connector 74. Each chamfer 86 may be at approximately 45 degrees, such that the collective angle defined by the chamfers 86 of the vertical edges 56 when the sides 46 are flat or at 180° relative to each other, is approximately 90 degrees.

The chamfers 86 can maintain proper alignment of the sides 46 as the panels 52 are pivoted through a range of motion, as shown in FIGS. 20-22. In FIG. 20, the panels 52 are flat or at 180° relative to each other, and it can be seen that the vertical edges 56 are not butted against each other, but rather a small gap G is maintained between the panels 52, as discussed above with respect the first embodiment. In FIG. 21, the panels 52 are folded to approximately 90° to each other to create the vertical corner 48. When folded, the hinge connector 74 is at least partially received within the notches 58 (not shown). In this position, the chamfers 86 can abut each other which can maintain alignment between the notches 58 and the hinge connectors 74 by preventing the vertical edges 56 from shifting relative to each other. In FIG. 22, the panels 52 are folded to approximately 0° relative to each other such that one panel 52 is stacked with the other panel 52.

The chamfers 86 allow 180 degree folding of the vertical corners 48 without stretching the hinge connector 74 excessively and beyond its capacity. Further, the chamfers 86 also allows the vertical edges 56 to be held together reasonably tightly, without gaps, and provides for a greater amount of surface contact area between panels 52, when the panels 52 are folded to approximately 90° to each other, i.e. when the box 40 is in its predominate mode of use. Ultimately, this gives the box 40 more horizontal rigidity. When unfolding the box 40 from the collapsed position, the chamfers 86 also help the vertical edges 56 come together without obstruction and requires less final adjustment to set up the box 40.

In all of the embodiments of the invention illustrated herein, the sides 46 are shown as being formed by a solid panel 52. However, in other embodiments of the invention, the sides 46 may be formed by other panels, including, but not limited to, panels with openings or latticework, panels made of multiple members, honeycomb panels, and laminated or composite panels. For example, in other embodiments the box may comprise a crate with substantially open sides

The box and methods of the above described embodiments provide a variety of benefits for collapsible boxes, including that notches 58 in the edges 56 of the sides 46 allows the sides 46 to be joined together while permitting the vertical corners 48 to fold between 0-180°. Due to the aligned notches 58 and gap G, the sides 46 can be folded through this range of motion without stretching the strap 64, 76 of the hinged connector 50, 74 and causing overextension of the hinge connector 50, 74, while still keeping the edges 56 firmly together at a right angle (90°) when the box 40 is assembled. The collapsibility of the box 40 is a useful feature in applications where a shipper desires to protect the contents of the box 40 during shipment, then collapse the box 40 and return it to the point of origin after shipment is complete. The collapsible feature minimizes shipping volume on the return trip and allows carriers to maximize the quantity of returned boxes in a shipment. The original shipper can then reuse the returned box 40 for future shipments.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. A collapsible box comprising: a plurality of sides, each side having at least one notched edge, with at least one notch therein, the at least one notch in register with a notch on an adjacent one of the sides; at least one hinge connector connecting two of the sides and comprising: first and second fasteners mounted to a respective one of the two sides; and a flexible strap between the first and second fasteners and aligned with the notches in register; whereby, due to the aligned strap and notches, the two sides can be folded through a range of motion with respect to each other.
 2. The collapsible box of claim 1 wherein the strap is at least partially received within the notches in register when the sides are oriented at less than 90 degrees to each other to allow the box to be folded flat.
 3. The collapsible box of claim 1 wherein the range of motion is 180-degrees.
 4. The collapsible box of claim 3 and further comprising a gap between the two sides when the sides are oriented at 180 degrees to each other.
 5. The collapsible box of claim 1 wherein the first and second fasteners are integrally formed on opposite ends of the strap.
 6. The collapsible box of claim 1 wherein the first and second fasteners comprises a plurality of nails extending laterally from the first and second fasteners.
 7. The collapsible box of claim 6 wherein some of the plurality of nails are disposed perpendicularly with respect to another some of the plurality of nails.
 8. The collapsible box of claim 1 wherein the first and second fasteners comprise first and second connector plates
 9. The collapsible box of claim 8 wherein the first and second connector plates comprise a plurality of nails pressed through the strap to connect the at least one hinge connector to a respective one of the two sides.
 10. The collapsible box of claim 1 wherein the plurality of sides comprises four sides, each of the four sides having first and second opposed notched edges disposed adjacent to another notched edge of another of the four sides, and wherein each set of adjacent sides is interconnected by at least one hinge connector.
 11. The collapsible box of claim 10 wherein the at least one hinge connector comprises two hinge connectors spaced from each another on the adjacent notched edges of the interconnected set of adjacent sides.
 12. The collapsible box of claim 1 and further comprising a base corresponding in periphery to an erected shaped of the plurality of sides.
 13. The collapsible box of claim 1 and further comprising a top corresponding in periphery to an erected shaped of the plurality of sides.
 14. The collapsible box of claim 1 wherein the at least one notch in each of the plurality of sides is rectangular.
 15. The collapsible box of claim 1 wherein the plurality of sides comprise panels.
 16. The collapsible box of claim 1 wherein the flexible strap has a width corresponding to a width of the at least one notch and wherein at least a portion of the flexible strap is received within the notch on a corresponding side.
 17. The collapsible box of claim 1 wherein the flexible strap comprises a metal strap.
 18. The collapsible box of claim 1 wherein the plurality of sides comprise at least one of plywood, laminated veneer lumber, laminated strand lumber, parallel strand lumber, or oriented strand board.
 19. The collapsible box of claim 1 wherein the at least one notched edge of each side comprises a chamfer.
 20. The collapsible box of claim 19 wherein the chamfers of two of the sides connected to the at least one hinge connector are provided opposite the at least one hinge connector on the sides. 